Share This Post:

CCPS’ Process Safety Boot Camp, AIChE Academy’s most popular course, was developed especially for companies looking to train their staff in the fundamental concepts of Process Safety. It is widely used by corporate training departments across different sectors of industry. Companies large, small and in-between use CCPS’ Process Safety Boot Camp to ramp-up staff knowledge to a common level quickly and easily.

In 2013, a public version of the course was created to allow individuals to attend singly or in small teams. Attendees join others from diverse industries and companies and gain a foundational knowledge of process safety and how it applies to their specific situation.

This intensive 4-day course is taught by two seasoned instructors, each with a minimum of 25 years of experience in process safety. The agenda covers key process safety areas including Risk Based Process Safety, Process Hazard Analysis, Regulatory Compliance and Process Safety in Plant and Design Operations.

Who Should Attend:

Technical staff in the process industries, pipeline industries, utility companies, and engineering service companies who need to move beyond an understanding of personal safety and learn the basics of Process Safety and Process Safety Management, including:

Chemical Engineers

Process Design Engineers

Manufacturing Engineers

Chemists

Mechanical and Reliability Engineers

Instrumentation/Automation Engineers

Shift Supervisors

Lead Operators

EHS Specialists

Managers who wish to gain a more comprehensive understanding of best risk based management system practices

Interested in taking this course outside of North America?

Don Abrahamson has over 40 years of experience in operations and engineering roles to draw from process safety management, operations management, process safety engineering, technical management, quality assurance management, process development and research. He recently retired from Celanese as the Global Process Safety Manager. He also worked for Occidental Chemical for over 32 years. He has conducted PHAs, Audits, Incident Investigations and /or Training on three continents: Americas, Europe and Asia. He has four US Patents from his work in research and...Read more

Scott Berger, now an independent consultant, served as Executive Director of CCPS for nearly 14 years. Scott also worked for 5 years at Owens Corning, where he held a range of Environment, Health, and Safety (EHS) assignments including Director of EHS Strategic Management. In addition, Scott worked for 18 years at Rohm and Haas Company in R&D, engineering, and EHS. Scott received a BS and MS from the Massachusetts Institute of Technology.Read more

Jack Chosnek has over forty years of experience in the petrochemical industry with involvement in process safety in the majority of them. He worked for Celanese Corporation for 25 years in R&D, Tolling, Pilot Plants, Operations, Process Engineering and Process Safety Management in management and staff positions. He is President and Principal at KnowledgeOne LLC, where he has consulted for companies in the chemical, refining, oil and gas, offshore, and LNG industries, implementing process safety management systems, facilitating PHAs and LOPA/SIL studies, conducting...Read more

Jim Conner joined CCPS as a Staff Consultant in 2011. He has 35 years of experience in chemical process engineering, chemical manufacturing operations, and R&D across operations in Asia, Europe, Middle East, and North America. Most recently Jim held the position of Sr. Vice President, Operations for Enerkem, a solid waste-to-chemicals startup venture. Prior to Enerkem, he served as Vice President, Operations and Technology for Celanese, with responsibility for domestic and international operations and R&D facilities. He also was accountable for the design and startup of a world-...Read more

Walt Frank is President of Frank Risk Solutions, Inc. and is a Fellow of both the AIChE and the AIChE Center for Chemical Process Safety (CCPS). He received his BSChE from Rose-Hulman Institute of Technology in 1973 and has worked in the process industries in various capacities for over 45 years, beginning as a lab technician for Pfizer while working his way through college. After graduation, he joined DuPont where, over 14 years, he held positions in plant technical support, manufacturing supervision, R&D, project design, and project start-up. He subsequently moved to...Read more

Dennis C. Hendershot is a chemical engineer with 40 years of experience in process research and development, plant design and startup, and process safety. From 1970 until his retirement in 2005 as a Senior Technical Fellow, he worked at Rohm and Haas Company. He then joined Chilworth Technology Inc. as a Principal Process Safety Specialist (retiring again in 2009), and the Center for Chemical Process Safety (CCPS) of the American Institute of Chemical Engineers as a Staff Consultant. With CCPS, he has worked with the Inherently Safer Design Subcommittee, the Risk Tolerance Criteria...Read more

John Herber joined CCPS in 2009 after a 33-year career with 3M Company that included positions in process and project engineering, production operations and corporate safety. In Corporate Safety Services, John developed programs for improving PSM systems across 3M’s global operations, including PSM metrics, Process Hazard Management policy and implementation guidance. As PSM consultant, John has performed audits, facilitated PHAs and assisted with PSM program development and training. John has a BS in Chemical Engineering from Purdue.

David Hill, President of Practical Process Safety LLC, has over 30 years of industrial experience. His careers range from Corporate Principal Risk Engineer for Occidental Chemical, Property Insurance Loss Prevention Specialist for Factory Mutual Global and Chief Engineer Officer for international cargo ship companies. His work experiences have taken him to over 85 countries. While working for Occidental Chemical for nearly 20 years, his responsibilities included developing, implementing, and applying process safety programs relating to mechanical integrity, hazard and consequence...Read more

Jerry Jones, PE joined CCPS as a staff consultant in 2012. He has 40+ years of experience across industry sectors including chemicals, polymers, pharmaceuticals, and electronics industry materials. He has worked in process development and engineering, plant design, EHS, and process safety functions and supported manufacturing operations in over a dozen countries while an employee of Monsanto, SRI International, Raychem, and Genentech/Roche. He has extensive experience with the implementation of risk-based management systems including those for process safety. He earned BS and ME...Read more

Kelly Keim retired as Chief Process Safety Engineer from ExxonMobil Research and Engineering after over 33 years of service. Following 15 years in several levels of management in operations and maintenance, Kelly found his passion in process safety. Kelly has led HAZOPs, risk assessments of many types, Layer of Protection Analysis (LOPA), inherent safety studies, fire protection surveys, pre-startup safety reviews, Management System reviews, and major accident hazard studies. In his final years, Kelly led ExxonMobil’s revamping of tools and methods for assessing and managing...Read more

Brian Kelly, P Eng, joined CCPS in 2005 as a staff consultant after 34 years of service with Imperial Oil and Syncrude Canada Ltd. Brian received his BASc and MASc degrees in chemical engineering from the University of Ottawa (Canada). Brian has special expertise in Process Safety Management audits in oil, gas and chemical sectors, Process safety training programs, and investigation of significant process incidents. In addition to Brian’s many accomplishments, he is the 2010 recipient of the Chemical Institute of Canada’s Process Safety Award for his many years of outstanding service to...Read more

Ellen Lenz has over 30 years of experience in the chemical industry holding positions in project management, research and development, process safety, and operations during her 22 years at Lyondellbasell Industries and 9 years at BASF Corporation.

Jack McCavit retired from Celanese Chemical Company after 35 years with experience in operations management and practical application of process safety management systems. Jack served as the BP Baker Panel’s technical project manager and was a part of the team that monitored BP’s implementation of the Baker Panel recommendations. Jack served as the committee chair for CCPS’s Guidelines for Risk Based Process Safety. He graduated from Texas Tech University with a BS in chemical engineering....Read more

Dan Miller retired in 2016 following a 39-year career with BASF. During the first half of his career, Dan managed operations of production facilities at BASF’s Geismar, Louisiana site, including the design, construction, commissioning and on-going operation of 8 new process plants employing varying technologies. In 1995, he transferred to BASF’s global headquarters in Ludwigshafen, Germany making the career path change into process safety. Between 1995-1999, Dan was involved in supporting the process safety evaluation of major capital investment projects in...Read more

John has over 40 years of experience in chemical manufacturing and process safety with jobs in the chemical industry, consulting and government. He is currently an independent consultant and retired from the U. S. Chemical Safety and Hazard Investigation Board where is was a lead investigator and the Dow Chemical Company where he was a leader in process safety.

Currently he provides process safety services as a independent consultant and serves as a staff consultant to the Center for Chemical Process Safety (CCPS). As a staff consultant for CCPS he has managed many book...Read more

Louisa Nara is the Technical Director of the Center for Chemical Process Safety (CCPS) for the American Institute of Chemical Engineers (AIChE). Louisa comes to AIChE/CCPS after 15 years with Bayer where she held positions of increasing responsibility including: Manager Process Safety and Crisis Management; Director of HSE, Security and Emergency Response at Bayer’s largest US Manufacturing site; and, Director, Risk Management and Compliance, NAFTA. Prior to joining Bayer, Louisa also gained significant experience in process safety, engineering, and HSE with Diamond Shamrock, PQ...Read more

Albert Ness joined CCPS in 2013 as a Process Safety Writer. Prior to that, Albert had 39 years of experience with Rohm and Haas, GE Plastics, The Dow Chemical Company and ABS Consulting as a research and development engineer in plastics, agricultural chemicals and Ion Exchange Resins and then, starting in 1989, as a process safety specialist. He was the Secretary/Treasurer and then a Director of the Safety and Health Division of the AIChE for 13 years, and a member of the NFPA 654 technical committee for combustible dusts for eight years as a representative from Rohm and Haas and then Dow...Read more

Frank Renshaw is a certified safety professional and certified industrial hygienist currently serving as an EHS consultant after 35 years with Dow Advanced Materials (formerly the Rohm and Haas Company).

He held various positions at Rohm and Haas including: EHS Director for Specialty Materials, Corporate Safety Director and Corporate Industrial Hygiene Director. He chaired the company’s Code of Safe Manufacturing Practice Committee, coordinated a business-wide initiative on closed system chemical operations, and led Major Accident Prevention studies involving acrylic coatings...Read more

Bob is currently a Staff Consultant and Instructor for CCPS. Bob has over 15 years in chemical production management, five years in project and process engineering management and 20 years in the safety, health and environment area. From 1997 through 2003, he was the Director of Emergency Response and Issue Management for BASF Corporation in Mount Olive, NJ. Since 2003, Bob has done Occupational Safety, Process Safety and Emergency Response consulting. Prior to 1997, Bob worked for Merck, Polaroid, Story Chemical, and Polysar.

Learning Outcomes:

List the four pillars and 20 different elements of risk based process safety.

Compare the different types of process hazard analysis techniques including an introduction to HAZOP.

Describe how process safety management should be used in coordination with process design and plant operations.

Discuss OSHA's and the EPA's regulations impact on process safety.

Explain the importance of inherently safer processes during plant design along with risk analysis and management.

Analyze the concept of layers of protection to prevent and/or mitigate loss of containment events.

Discuss the principles of Risk Analysis and Risk Management.

Course Overview

DAY 1

Introduction

Occupational safety vs. process safety

Business case for process safety

Key principles of process safety

Anatomy of an Incident

Loss of Containment

Containment and control

Prevention

Mitigation

DAY 2

Introduction to Management Systems and Risk Based Process Safety

Process Safety Culture Compliance with Standards

Inherently Safer Concepts

Process Design

Process Safety Competency

Workforce Involvement

Human Factors

Stakeholder Outreach

Process Knowledge Management

Understanding Material Hazards

DAY 3

Specific Hazards

Chemical hazards

Reactivity

Toxicity

Corrosivity

Inherent Safety

Hazard Identification and Risk Analysis

Hazard evaluation techniques

Consequence and Impact Frequency

Risk Analysis

Risk criteria

Risk acceptance

Operating Procedures

Safe Work Practices

DAY 4

Hot Work Permits, etc.

Asset Integrity and Reliability

Contractor Management

Training and Performance Assurance

Management of Change (MOC)

Operational Readiness & PSSR

Conduct of Operations

Emergency Management

Incident Investigation

Measures and Metrics

Auditing Compliance

Management Review and Continuous Improvement

Additional EPA RMP regulations

Course Wrap up

Who Should Attend

Who Should Attend:

Technical staff in the process industries, pipeline industries, utility companies, and engineering service companies who need to move beyond an understanding of personal safety and learn the basics of Process Safety and Process Safety Management, including:

Chemical Engineers

Process Design Engineers

Manufacturing Engineers

Chemists

Mechanical and Reliability Engineers

Instrumentation/Automation Engineers

Shift Supervisors

Lead Operators

EHS Specialists

Managers who wish to gain a more comprehensive understanding of best risk based management system practices

Testimonials

The following are testimonials from people who recently took this course:

Course was very well managed and maintained. Great instructors with a lot of relevant experience. Well taught. - J. Bredsguard, Process Safety Engineer, Bechtel

This course was a great basis for PSM and RBPS and will help get me off on the right foot in my career as a PSM Engineer. The instructors were excellent and draw from a wealth of experience in several industrials to give a full picture of RBPS and PSM. - P. Muldowney, PSM Engineer, Akzo Nobel

This course gave me the "What's In It For Me" (WIFM) rather than just compliance. - D. Hurban, Principal Engineer, American Electric Power

This course exceeded my expectations. I am leaving this course with a good understanding of Best Practices of Risk Based Process Safety.

Very helpful in understanding PSM and what is necessary for implementing/improving current PSM program. Examples, class participation and working examples/exercises very helpful. - T. Smith, Process Engineer PSM/HSE

I really enjoyed learning about how to create a positive process safety culture.

Overall, the course was very informative, thorough in course material, and provided excellent video examples to drive the point home. It was fun!

Excellent - the speakers brought with them a realm of experience that added tremendously to the experience. - K. Koehler, PSM Coordinator, Luminant Power

Excellent. Very useful information, case studies, discussions on best practices and perspective that will definitely help me contribute to enhance process safety in my company. M. Moreno, EHSS Manager

Great course! Builds a good foundation of PSM for professionals early in their PSM careers. - T. Vodopivec, Superintendent PSM, Valero Energy

FAQs

Find answers to questions about registration and refunds, tuition and fees, travel and lodging (for location-based courses), how eLearning courses work, how credits work, and more.